EP3322573B1 - Verfahren und vorrichtung zur baumaterialdosierung in einem generativen fertigungsverfahren - Google Patents

Verfahren und vorrichtung zur baumaterialdosierung in einem generativen fertigungsverfahren Download PDF

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Publication number
EP3322573B1
EP3322573B1 EP16739077.2A EP16739077A EP3322573B1 EP 3322573 B1 EP3322573 B1 EP 3322573B1 EP 16739077 A EP16739077 A EP 16739077A EP 3322573 B1 EP3322573 B1 EP 3322573B1
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EP
European Patent Office
Prior art keywords
layer
powder
recoater
building material
solidified
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EP16739077.2A
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German (de)
English (en)
French (fr)
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EP3322573A2 (de
Inventor
André DANZIG
Rainer Salzberger
Jochen Philippi
Andreas Baumann
Gerd Cantzler
Robert Jelin
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EOS GmbH
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EOS GmbH
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J4/00—Feed or outlet devices; Feed or outlet control devices
    • B01J4/02—Feed or outlet devices; Feed or outlet control devices for feeding measured, i.e. prescribed quantities of reagents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/37—Process control of powder bed aspects, e.g. density
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/50—Means for feeding of material, e.g. heads
    • B22F12/55—Two or more means for feeding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/50—Means for feeding of material, e.g. heads
    • B22F12/57—Metering means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/60—Planarisation devices; Compression devices
    • B22F12/67—Blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/141—Processes of additive manufacturing using only solid materials
    • B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/205—Means for applying layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/307—Handling of material to be used in additive manufacturing
    • B29C64/321—Feeding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/307—Handling of material to be used in additive manufacturing
    • B29C64/343—Metering
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/386—Data acquisition or data processing for additive manufacturing
    • B29C64/393—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/165—Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the present application relates to a manufacturing device for the additive layer-by-layer manufacturing of three-dimensional objects and to a correspondingly adapted dosing device.
  • the present invention relates to devices and methods in which the building material is in powder form.
  • a layer of building material is usually applied in a building chamber on a height-adjustable carrier and selectively solidified. This process is continued by repeated application and solidification of layers until the three-dimensional object has been completed by the selective solidification of the layers stacked on top of one another.
  • DE 10 2011 121 568 A1 describes a generative layer construction method in which a powdery metal material is selectively solidified by means of electromagnetic radiation or electron radiation. In particular devotes itself DE 10 2011 121 568 A1 the problem that the powder application usually always takes place over the entire area of the existing building chamber. On the one hand, this leads to an extended production period because a large-area layer is applied, even if only a small fraction of this layer is actually solidified. There is also the disadvantage that large amounts of powder are consumed, although only a fraction of the powder is actually solidified.
  • High powder consumption is disadvantageous for several reasons. If you disregard the resulting high building material costs, there is also the disadvantage that other resources, for example the powder handling systems (sieves, conveyor systems) are exposed to increased wear due to their more frequent use. In particular if very high objects are being built, the build time can be extended by the need for powder refilling. In the worst case, the overall height of the objects to be manufactured is limited if a powder refilling process is inappropriate. Reuse of unconsolidated powder that has already been used in a device for additive layer-by-layer production is only possible to a limited extent because the powder ages in the device. DE 10 2007 006 478 A1 describes a dosing device for use in a manufacturing device for manufacturing a three-dimensional object.
  • the object of the present invention is therefore to provide a method and a device which allow an alternative optimization of the powder dosing without necessarily accepting the presence of boundary walls made of the building material and not belonging to the object.
  • FIG. 1 schematically shows a laser sintering or melting device as an example of such a device for the layered production of a three-dimensional object by means of a generative manufacturing process.
  • the device has a building container 1 which is open at the top and to which the building material for the layer-by-layer manufacturing process is fed and which laterally surrounds the building material during the layer-by-layer manufacturing process.
  • a carrier 2 which can be moved in the vertical direction carries a construction platform which in turn carries the object 3 to be formed.
  • the construction platform can also be dispensed with. Due to the horizontal dimensions of the building container 1, a construction field 22 (see Fig. 2 ) Are defined.
  • a coater 5 is provided for applying the powdery building material that can be solidified by electromagnetic radiation or particle radiation to already solidified layers of the object 3 or, at the beginning of the building process, the building platform itself.
  • An in Fig. 1 shown exposure system used for powder consolidation has a laser 6 as the source of the electromagnetic radiation.
  • Another component of the exposure system is a deflection device 8, through which a laser beam 7 generated by the laser 6 is directed onto a coupling window 9, from which the beam penetrates into the process chamber 10 and hits a predetermined point in the building level 4.
  • the process chamber 10 is preferably floodable with a protective gas in order to avoid reactions of the powder with the ambient atmosphere.
  • the device comprises a control unit 11, via which the deflection device 8, the vertical movement of the carrier 2, the coater 5 and a height-moveable (feed) stamp 12b in a metering container 12a are controlled in a coordinated manner for carrying out the construction process.
  • the control unit 11 can also control further components of the device.
  • the control unit 11 has access to CAD data of the object to be produced, which serve as the basis for the control.
  • All powders or powder mixtures suitable for a generative layer construction process, in particular for a laser sintering or melting process, can be used as the powdery building material.
  • the method according to the invention can be used in the same way when using plastic powder or ceramic powder or plastic-coated sand.
  • the laser sintering device is operated in such a way that the coater 5 travels over the construction field and applies a powder layer with a predetermined thickness d2.
  • the cross section of the object 3 in the respective layer is then irradiated with the laser beam 7, whereupon the powder melts at least partially and solidifies during the subsequent cooling.
  • at least partial melting it is meant that the powder particles melt at least only on the surface, but if desired also completely. It would also be possible to soften the powder grains only, which, upon subsequent cooling, also leads to a connection thereof to a solid.
  • the carrier is then lowered by an amount d2 and a new powder layer of thickness d2 is applied.
  • the object 3 is produced in this way layer by layer. After completion, object 3 is removed and, if necessary, aftertreated and / or subjected to a quality control.
  • the powdery building material available for a coating process is located in a metering container 12a next to the building container 1.
  • a metering container 12a By lifting the plunger 12b in the metering container 12a, powder material is pushed upwards, which can then be pushed by the coater 5 onto the building field and there can be distributed.
  • the amount of powder made available can be controlled via the height difference S D by which the plunger 12b is moved upwards in the metering container 12.
  • the plunger 12b and the metering container 12a act as a metering device 12 to measure the amount of powder to be used for a layer application.
  • Fig. 2 shows a top view of the construction level 4 of the device in FIG Fig. 1 .
  • the dosing container 12a and, provided with the reference number 13, an overflow container, in which the in Fig. 2 not shown coater 5 excess building material is pushed after a layer application.
  • the coater 5 would be in Fig. 2 move from right to left.
  • Length L D and width W D of the metering container 12a or feed plunger 12b are equal to the length L BF or width W BF of the construction field 22. This need not be so, but it makes sense at least if the length L D of the metering container is the same the length L BF of the construction site, since otherwise powder may be pushed through the coater 5 next to the construction site. As already mentioned, in Fig. 2 the coater 5 move in the direction of the width W BF of the construction field 22.
  • Fig. 3 shows a side view of the object 3 during the construction process.
  • the currently top layer of the object 3 is shown, which has already been solidified and is flanked on the left and right by unconsolidated powdered building material 18, hereinafter referred to as "powder material" for short.
  • a new powder material layer 31 has already been applied by means of the coater 5 to the previous layer solidified in the area of the object 3, ie the coating process has already been completed.
  • d1 is intended to denote the thickness of the previous powder layer before it is solidified.
  • the powder compaction factor PV is intended to characterize the percentage by which the thickness of the preceding layer has decreased as a result of the consolidation. It should also be noted that, in a first approximation, it can be assumed that d1 is equal to d2. However, a layer just applied could have a thickness slightly different from d2 due to thermal processes or settling processes, although it was applied with the thickness d2. This should be taken into account by introducing size d1.
  • the amount of powder P2 additionally required to compensate for the shrinkage during solidification can be taken into account as a whole simply by increasing the amount of powder P1 required for coating the entire construction field with an intended thickness d2 by a fixed amount of safety.
  • the additional powder quantity P2 required to compensate for the shrinkage is not chosen to be the same for each layer, but rather is chosen as required:
  • the additional amount of powder P2 required depends on the area A of the last solidified object cross section.
  • the control unit 11 accesses the CAD data of the object to be produced before applying a new powder layer and determines the area A of the solidified area in the last powder layer applied. Based on this area A, the amount of powder additionally required for the compensation of the shrinkage is then made available for the layer application.
  • the powder consumption can be further optimized according to the method according to the first embodiment:
  • the inventors assumed that the orientation of the last exposed area in the construction field influences the amount of powder additionally required to compensate for the powder compaction in the exposed area.
  • This is supposed to 4a and 4b are illustrated. In both figures, a layer is applied in the horizontal direction on the surface of the building site 22 shown.
  • the cross section of the object 3 solidified in the previous layer is shown as an elongated rectangle for the sake of simplicity.
  • the area of the last solidified component cross section is the same with the position of the cross section in Fig.
  • the control unit 11 checks the position of the last exposed object cross section within the construction field 22. For this purpose, the control unit 11 divides the construction field into n (n> 1) narrow strips 221. The strips 221 extend in the x direction, that is, in the direction of the width W BF of the construction field 22 or in the direction of travel of the coater 5. Using the CAD data of the object to be produced, the control unit 11 can first determine which strip the in the previous powder layer solidified Object cross section is available. The CAD thickness also shows the original thickness d1 of the previous powder layer.
  • control unit 11 now determines the extent x i in the x direction (the direction of travel of the coater 5) of the object cross section in this strip for each strip 221 in which the object cross section solidified in the previous powder layer is present.
  • the maximum (MAX) of the strip-wise products from extension x i in the direction of travel of the coater 5 and layer thickness d1 of the previous powder layer is then used to determine the additional powder quantity P2 required for the shrinkage compensation.
  • the layer thickness d1 of the previous powder layer is the same for all strips, it is clear that the product does not have to be determined for each strip separately, but only the maximum value xmax of the strip-wise dimensions x i can be determined first and then with the layer thickness d1 Obtaining the maximum (MAX) can be multiplied.
  • the method according to the first embodiment ensures that enough powder is applied to all points of the last solidified object cross-section to compensate for the shrinkage due to the powder compaction. At the same time, powder consumption is kept to a minimum.
  • the determination of the maximum extent of the last solidified object cross section in the x direction is the more accurate, the smaller the strip width when breaking down the construction site into strips.
  • An exemplary value for the strip width could be a value between 1 and 2 centimeters.
  • an alternative approach is also possible in which the maximum extent in the x direction is determined in a different way, not by means of the strip decomposition described. After all, the width of the individual strips does not have to be the same for all strips. Depending on the cross section of the object, it may be advisable to choose different widths for at least some of the strips.
  • Fig. 5 the last solidified object cross section is shown in one piece.
  • a plurality of non-interconnected object cross sections are solidified in one layer, for example if several objects are produced at the same time or if there are different projections in the direction of construction (z direction) for one object. It is then important to determine and add up the dimensions of the individual object cross sections in the x direction.
  • the maximum value of the strip-wise accumulations over the dimensions of the object cross sections in the direction of travel of the coater (5) is determined and multiplied by the layer thickness d1.
  • sum i is the sum of the dimensions of the individual object cross-sections in the x-direction within a strip i
  • maxsum i is the maximum value of the strip-wise summations of the dimensions.
  • MAX maxsum i * d 1 .
  • the safety factor SF is a device-dependent parameter and can be determined by preliminary tests, in which the powder loss when a layer is applied is determined. It will depend on the manufacturing device actually used. The clarity for the sake of safety the safety factor is not given in detail in all equations that describe the additional powder quantity P2.
  • the value for the powder compaction factor PV is a material-dependent constant and can also be determined in advance after simple preliminary tests for a specific building material, in which the shrinkage when compacting the building material under the desired consolidation conditions (e.g. powder temperature, laser power, etc.) is determined.
  • the described amount of powder can thus be adapted exactly to the required amount of powder by the described method, so that powder losses due to overdosing can be avoided and powder can thus be saved.
  • different layer thicknesses of the powder are solidified in an object cross section in different areas.
  • solidification takes place after the application of a powder layer with a specific layer thickness (for example 20 ⁇ m) in each case in the edge region (contour region or shell region) of an object cross section.
  • the interior of an object cross section is only consolidated every m layers, e.g. every three layers, i.e. only after every mth layer application.
  • an additional powder layer thickness d11 was introduced, the extent x11 of the solidified area of the thickness d11 in the x-direction being multiplied by the thickness d11 for each strip and for this the product of the extent x1 of the solidified area of the thickness d1 in the x-direction the thickness d1 is added (the x-direction is the direction of the width W BF of the construction field 22).
  • the maximum value max i of the values determined in strips in this way is then used as a basis for determining the additional powder quantity P2.
  • the maximum value maxi thus corresponds to the above maximum MAX.
  • Fig. 6 the procedure is briefly illustrated again: A thickness d11 of the last solidified powder layer is present in the core region 33 and a thickness d1 is present in the hatched contour region 32.
  • S D the extent of the solidified areas 33 is summed and the sum multiplied by the thickness d11, and for this purpose the product of the sum of the dimensions of the solidified areas, within each strip in which there is an object cross section solidified in the previous powder layer Areas 32 added in the x direction with the thickness d1.
  • the maximum value of the values determined in this way in strips is then determined and the dosage of the additional powder quantity is used as a basis (the additional powder quantity is selected in proportion to this maximum value).
  • the procedure is not limited to the presence of only two different layer thicknesses in the last solidified area.
  • Sumx1 is the sum of all dimensions in the x-direction of the solidified areas of thickness d1 present within a strip
  • sumxj is the sum of all dimensions in the x-direction of the solidified areas of thickness dj
  • sumxk is the total of all dimensions in the x-direction of the solidified areas of the thickness dk present within a strip.
  • the length of the metering device L D is preferably also the length of the construction field L BF in the second embodiment.
  • the metering device 12 which is in the device of Fig. 1 is shown, designed in a special way, namely in such a way that in the direction of the width W D of the metering container 12a, that is to say perpendicular to the direction of movement of the coater 5, a plurality of feed rams 12b are arranged adjacent to one another.
  • Each of the feed rams 12b can be adjusted in height independently of the other feed rams 12b by means of a height adjustment device.
  • the control unit 11 can thereby control the feed punches 12b in such a way that they are raised to different extents before the application of a new layer. This makes it possible to provide different amounts of powder for the layer application along the length L BF of the construction field 22, that is to say perpendicular to the direction of movement of the coater 5.
  • the powder application can be optimized to a particular degree with the described configuration of the metering device 12: Before the application of a new powder layer, the control unit 11 determines at which points in the y-direction, that is to say perpendicular to the direction of movement of the coater, the last solidified object cross section or the last solidified object cross sections are located. At these points, the metering device 12 can then increasingly provide powder by moving the corresponding feed rams 12b upwards by a larger amount.
  • the dosing device 12 according to the third embodiment can also be combined with the devices for the layer-wise generative production of three-dimensional objects, as described in the first and second embodiments.
  • each of the methods described in connection with the first and second embodiment, including the modification options described there, can also be carried out using the metering device 12 described in the third embodiment.
  • each strip corresponds to the strip disassembly carried out by the control unit 11, exactly one feed stamp 12b.
  • each strip is chosen so that it corresponds to a feed stamp in the direction of the width W BF of the construction field, its width being equal to the width of the feed stamp.
  • the required amount of powder which was determined taking into account the extent of the last solidified object cross-section in the direction of the width of the construction field 22 within this strip, can be supplied to each strip (exactly).
  • Each of the feed punches 12b is then raised by an amount that was determined based on the maximum value of the required powder volume in the strips (possibly only one) that are "assigned" to this feed stamp 12b.
  • S D W BF * d 2nd + SF + MAX * PV / W D
  • the maximum MAX is not formed over all strips, but only with respect to the strips "assigned" to a feed stamp 12b.
  • the coater 5 pushes the application powder onto the construction field 22 after the feed rams 12b have been raised in the metering device 12.
  • the coater 5 can advantageously be provided with dividing walls, which are are walls that extend in the direction of movement of the coater 5.
  • Partitions are expediently located precisely at those points at which two feed rams 12b adjoin one another.
  • the dimensions of the individual stamps perpendicular to the direction of movement of the coater do not all have to be the same.
  • the strip widths y i need not all be the same for each other in the strip decomposition.
  • a coater 15 is used, in which a metering device is already integrated.
  • the application principle with such a coater 15 is based on Fig. 7 described, which shows a schematic lateral section through the coater 15 above the construction field 4:
  • Fig. 7 a snapshot is shown while the coater 15 is traveling over the building level 4 in the direction of movement B.
  • Solidified layer regions can be seen in the object 3 in the sectional view.
  • No layering is shown in the powder 18 which has remained unconsolidated from previous layer applications.
  • the heights of solidified layer areas and powder that has remained unconsolidated are shown the same, although this is particularly the case Fig.
  • the coater 15 essentially consists of two application blades 16 which are arranged at a distance from one another in the direction of movement B.
  • the blades 16 extend parallel to one another perpendicular to the direction of movement B, preferably over the entire length L BF of the construction site, ie the length of the coater L D perpendicular to its direction of movement is preferably equal to the length L BF .
  • the coater 15 has a storage space 17 with a powder supply 37 necessary for the application of a layer 31.
  • the storage space 17 has an opening 20 at its lower end through which construction material 15 can escape during the movement of the coater forms a layer of thickness d2.
  • the storage space 17 is divided into a plurality of storage chambers 17a, 17b, which are arranged in a direction perpendicular to the direction of movement (in Fig. 7 into the sheet plane) are arranged adjacent to each other.
  • Fig. 8 in this context shows an embodiment of a coater when viewed obliquely from above, that is to say from the same lateral viewing position as in FIG Fig. 7 , but with an elevated location of the viewer.
  • the coater has a linear arrangement of the storage chambers 17a, 17b in a direction perpendicular to the direction of movement of the coater.
  • the specialty of the coater from Figure 8 is that two storage chambers 17a and 17b are arranged in the direction of movement of the coater. In general, however, this does not have to be the case and one could also dispense with the subdivision into the chambers 17a and 17b in the direction of movement of the coater.
  • the coater 15 with the plurality of storage chambers can thus be regarded as a metering device in which the storage chambers arranged in a direction perpendicular to the direction of movement of the coater can be viewed as a plurality of powder feed devices which can independently determine the amount of the powder material to be applied during the coating application:
  • the presence of several storage chambers in a direction perpendicular to the direction of movement of the coater makes it possible to supply different amounts of powder at different points in the construction field 22 in the direction perpendicular to the direction of movement, since the storage chambers can have different filling quantities along the direction perpendicular to the direction of movement.
  • the coater according to the invention thus enables powder-saving layer application, for example in the in Figure 4b Case shown: Only those storage chambers which cover the already solidified area 3 during the layer application must have an additional powder amount P2 in addition to the powder amount P1 for a layer of thickness d2, by means of which the shrinkage in the solidified area 3 is compensated for. It is therefore also possible here (essentially) to hold exactly the powder requirement previously determined in accordance with the respective calculation formulas in the respective storage chambers arranged perpendicular to the coating direction, in order to achieve an optimized powder metering on the basis of the previously determined powder requirement. It would be furthermore even possible to apply a new building material layer only in the area of object 3, but not in other areas of the building field.
  • FIG. 8 Sliders 19a, 19b can be seen, with which the openings 20a, 20b on the bottom of the storage chambers 17a and 17b can be closed independently of one another.
  • a powder discharge from some of the storage chambers can optionally be prevented or throttled.
  • a powder supply to selected positions of the construction site can thus be switched off in a direction perpendicular to the direction of movement.
  • the degree of opening of the closing devices 19a, 19b can be controlled.
  • the amount of powder to be fed to the construction field at different points perpendicular to the direction of movement can be adjusted in a particularly simple manner: instead of adjusting the amount of powder to be fed in via the degree of filling in the storage chambers, the powder discharge rate is simply adjusted via the degree of opening of the opening at the bottom of a storage chamber.
  • At least one of the storage chambers is filled with a powder material which is different from the powdery building material 18 located in other storage chambers. In this way, for example, different sections of an object can be produced from different construction materials.
  • FIG. 8 The particular embodiment shown of a coater acting as a metering device is characterized in that there are two storage chambers 17a and 17b at a position along the direction perpendicular to the direction of movement.
  • the respective second chamber can initially only be filled at those points along the direction perpendicular to the direction of movement where a particularly large amount of powder is required for powder application.
  • the particular advantage of providing two (or even more) storage chambers at one position results, however, if the storage chambers 17a, 17b are filled with different materials. In such a case, the corresponding actuation of the closing devices 19a and 19b sets which material is used for the layer application during the movement of the coater at a position perpendicular to the direction of movement.
  • the building material it is thus possible to set the building material to be fed in for any point in the construction field. While the precise adjustability of the powder material to be fed in the direction of movement of the coater is limited in principle by the speed of actuation of the closing devices 19a, 19b relative to the speed of movement of the coater, the positional accuracy in the direction perpendicular to the direction of movement is determined by the number of metering chambers 17a, 17b or their respective Expansion specified perpendicular to the direction of movement. Thus, different materials can be applied not only transversely to the coating direction, but also in the same locally and in a controlled manner by appropriate selection of the metering chambers 17a, 17b.
  • FIG. 9 to 12 each show lateral cross sections of the specially modified coater and Fig. 13 a plan view of the further particularly modified coater, wherein the storage chambers 170a, 170b or 180a to 180c or 190a, 190b arranged one behind the other in the direction of movement are shown.
  • a majority of the in 9 to 12 The pairs or triples of storage chambers shown are thus arranged in a corresponding coater 150 or 180 perpendicular to the direction of movement (ie into the plane of the drawing sheet) next to one another. Each of these pairs or triples can therefore be regarded as a powder feed device already mentioned above.
  • each of the storage chambers 170a, 170b or 180a to 180c or 190a, 190b is provided with a closing device, by means of which a powder outlet at the lower end of the storage chambers can be switched on and off.
  • a closing device for example, B. closable flaps, sliders, nozzles or a slat closure as a closing device.
  • the special feature of the specially modified coater is that Figure 9 refer to.
  • the pair of storage chambers 170a, 170b shown there can be pivoted in the coater 150 via a pivot axis 151 extending perpendicular to the direction of movement of the coater. It is thus possible, for example when switching from the powder supply from the storage chamber 170b to the powder supply from the storage chamber 170a, to simultaneously pivot the pair of storage chambers by correspondingly actuating the closing devices (not shown). While in the left half of the Figure 9 the outlet of the storage chamber 170b is arranged above the outlet opening 175 arranged below the pair of storage chambers, is in the right half of the Figure 9 the storage chamber 170a is arranged above the outlet opening 175 which is stationary in the coater. With both in Figure 9 The positions of the pair of storage chambers shown thus get powder through the same outlet opening onto the construction field, so that switching from one storage chamber to the other does not change the location relative to the coater at which build-up material emerges from the coater.
  • a separate outlet opening 175 assigned to each of the existing storage chamber pairs 170a, 170b in the coater It is just as well possible to assign a plurality of adjacent storage chamber pairs to a common outlet opening 175, which then has an elongated shape and extends transversely to the direction of movement of the coater.
  • a common outlet opening 175 can also be assigned to all the storage chamber pairs lying next to one another in the coater.
  • the pivoting of a pair of storage chambers about the pivot axis 151 can be accomplished by means of servomotors or stepper motors or piezomotors. It can also be provided that several pairs of pantries are pivoted together, which do not necessarily have to lie next to one another. In particular, several pairs of pantries can also be assigned together to one servomotor.
  • the pivot axis can be a shaft extending through several pairs of storage chambers, in particular also a shaft extending along the entire coater, on which the pairs of storage chambers are rotatably mounted. However, such a common shaft could also be dispensed with, so that the individual pantry pairs are each equipped with their own shaft.
  • the actuation of the locking devices in the storage clamps and the pivoting can be coordinated with one another by suitably selected control signals.
  • Another possibility is to actuate the closing devices by means of the pivoting process, for example by means of a mechanical movement coupling of the pivoting process with a movement of the closing devices and / or using a spring-based mechanism.
  • Fig. 10 shows a pantry pair with modified openings on the undersides.
  • the storage chambers are provided on their underside with a slope 152a, 152b.
  • the lower edges of the storage chambers are essentially parallel to the working plane 4, in order to allow unimpeded powder to escape from the storage chambers into the outlet opening 175 (not shown).
  • Fig. 11 also shows a pair of pantries with modified openings on the undersides.
  • Fig. 11 are the pantries on their underside with a curve 153a, 153b Mistake.
  • the lower edges of the storage chambers for different swiveling positions are essentially parallel to the working plane 4.
  • powder can escape substantially unhindered even during the swiveling movement, which enables the powder application to be accelerated.
  • FIG. 12 shows those pivot positions at which powder emerges from the storage chamber 180a or the storage chamber 180c into an outlet opening 175 (not shown) in the coater. In the middle position, not shown (when the pantry triplet is not pivoted), the lower opening of the pantry 180b would lie above the outlet opening 175. In the Fig.
  • Fig. 13 shows, as already mentioned, a further special modification of the coater of the fourth embodiment. It is Fig. 13 a very schematic top view of the coater.
  • Fig. 13 Pairs of storage chambers 190a, 190b, which are arranged one behind the other in the direction of movement in the coater. Similar to 9 to 12 the storage chamber pairs are in turn moved such that either one or the other storage chamber is above the schematically illustrated position of the outlet opening 175.
  • special modification does not pivot the pantry pairs, but a horizontal displacement in or against the direction of movement, which in turn can be accomplished by servomotors. Otherwise, all the details and variation options are related Figure 9 to 12 have been described in the same way on the implementation of Figure 13 applicable.
  • the dosing device according to the fourth embodiment of the invention can also be combined with the devices for the layer-wise generative production of three-dimensional objects, as described in the first and second embodiments.
  • each of the methods described in connection with the first and second embodiments, including the modification options described there, can also be carried out using the metering device according to the invention in accordance with the fourth embodiment.
  • volume P 1 i + volume P 2nd i y i * W BF * d 2nd + SF + y i * PV * x 1 i * d 1 + ... + xj i * dj + ...
  • the dimensions of the individual storage chambers perpendicular to the direction of movement do not all have to be the same.
  • the strip widths y i need not all be the same for each other in the strip decomposition.
  • a plurality of strips can also be assigned to a storage chamber, in which case the total extent of these strips perpendicular to the direction of movement of the coater is then equal to the extent of the associated storage chamber perpendicular to the direction of movement of the coater.
  • the fourth embodiment of the invention can also be modified so that on in Fig. 1 and 7 a powder metering device is arranged on the left and / or right side edge of the construction field 22, which is subdivided perpendicular to the direction of movement of the coater in the same way as the coater and the individual storage chambers of the coater separately feed the powder quantities P1 i and P2 i .
  • the application device 15 can also have only one application blade 16, it being ensured that the powder from the storage chambers always reaches the application blade 16 in the direction of movement of the application device.
  • the shape of the storage chambers in the coater There are a multitude of options for the shape of the storage chambers in the coater. The easiest way to implement a rectangular or square cross section. There are also a multitude of possibilities for the dimensions of the storage chambers parallel to building level 4. The smaller the dimensions, the higher the accuracy when applying the powder. It is therefore conceivable, for example, to increase the maximum diameter of the storage chambers parallel to building level 4 to at least 0.2 mm, preferably at least 0.5 mm, particularly preferably at least 1 mm and / or at most 10 mm, preferably at most 5 mm, particularly preferably at most 2 mm put.
  • the present invention has been described in all embodiments using a laser sintering device, it is not restricted to laser sintering or laser melting. It can be applied to any method for producing a three-dimensional object by applying it in layers and selectively solidifying a powdery building material.
  • a laser instead of a laser, an LED (light-emitting diode), an LED array, an electron beam or any other energy or radiation source that is suitable for solidifying the powdery building material can be used.
  • the invention can also be applied to selective mask sintering, in which a mask and an extended light source are used instead of a laser beam, or to absorption or inhibition sintering. It is also possible to use it in a 3D printing process in which an adhesive is added to selectively solidify the powder material.
  • the present invention in all embodiments is not limited to a rectangular construction area 22 or a coater moving in a straight line over the construction area.
  • the coater can also have a curved instead of a linear shape and / or can be moved over the construction field following a curvilinear travel path.
  • the strips do not necessarily have to be straight when stripping, although they should have a constant strip width.
  • the metering devices of the third and fourth embodiment also do not necessarily have to be arranged in a straight line next to one another, but the arrangement can be adapted to the shape of the coater.
  • the method described above can be implemented partially or entirely by means of hardware components or else completely be implemented in the form of a computer program, which is executed by the control unit 11.
  • the control unit 11 can also comprise units spatially separated from the manufacturing device, in particular a precalculation unit or powder requirement determination unit, which determines the total amount of additional powder required for a shift in the manner according to the invention during operation.
  • the powder requirement determination unit preferably has a layer data input unit, a powder quantity determination unit, which is set up in such a way that it uses data received from the layer data input unit of a partially solidified powder layer of thickness d1 and the direction information received via the layer data input unit about the direction of movement of a coater (5) in a manufacturing device for producing at least one three-dimensional object (3) by means of successive layer-by-layer solidification of a powdery building material, the maximum (MAX) of the product from the expansion of this solidified area in the partially solidified layer in the direction of movement (B) of the coater (5) and the layer thickness d1 and for the application of a layer of thickness d2 following the partially solidified layer during production, defines an additional powder quantity (P2) which is proportional to the value of the maximum (MA
  • the layer data input unit and the additional powder quantity output unit are preferably interfaces for receiving or outputting data.
  • the shift data input unit intervenes e.g. to the computer-aided model of the object to be produced, which the control unit 11 or other parts of the control unit 11 also accesses for the production process. Furthermore, it is possible for the layer data input unit to receive information about the last solidified layer from the control unit 11 or other parts of the control unit 11 or manufacturing device.
  • the additional powder quantity output unit outputs the data describing the additional powder quantity P2 to the control unit 11 or other parts of the manufacturing device.
  • At least one additional powder quantity is added to the powder quantity required for a layer of thickness d2, which is proportional to the value of the maximum of the product from the extent of the solidified area of the previously applied layer in the direction of movement of the coater and its layer thickness.

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EP16739077.2A 2015-07-13 2016-07-08 Verfahren und vorrichtung zur baumaterialdosierung in einem generativen fertigungsverfahren Active EP3322573B1 (de)

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RU2018100902A3 (ja) 2019-09-11
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CN107835739A (zh) 2018-03-23
WO2017009249A3 (de) 2017-07-20
CN107835739B (zh) 2020-03-20
EP3322573A2 (de) 2018-05-23
US20180222112A1 (en) 2018-08-09
US20220274323A1 (en) 2022-09-01
WO2017009249A2 (de) 2017-01-19
KR20180084730A (ko) 2018-07-25
RU2717802C2 (ru) 2020-03-25
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